Digitally signed by

DEVELOPMENT CONSULTANTS
Ashish Kumar Neogi
PRIVATE LIMITED
Reviewed for general conformance with Contract
DN: cn=Ashish Kumar
Neogi, o=DCPL,
drawings and specifications.

PACKAGE : COAL HANDLING PLANT

ACTION : 5

ou=Power-B,
1 Approved 4 Disapproved.

Approved except as
For information/reference
2 noted. Forward final 5 only.

email=neogiak@in.dc
drawing.
Approved except as Information category with
3 noted. Resubmission 6 comments. Resubmission
required. required.

Approval of Contract documents by the Consultant shall

not relieve the Seller of his responsibility for any errors
lgroup.com, c=IN
Date: 2016.09.06
and fulfilment of Contract requirements.

EQUIPMENT: PADDLE FEEDER 11:37:36 +05'30'

VENDOR DRAWING NO: - O15147-M-BM-EQ-DC-0008

VENDOR: LARSEN & TOURBO LIMITED

2 Revised as per Letter No OPGC/BOP/5544/25-06-2016 25-07-2016 NZA RS RS

This document from Project specific Vendor supercedes
the earlier submitted document by BGRE. This
1 26-05-2016 NZA RS RS
document takes care of the comments given by
OPGC/DCPL.
0 SUBMITTED FOR APPROVAL 07-08-2015 K.P.K S.S N.S

REV DESCRIPTION DATE PPD CHKD APPD

OWNER
ODISHA POWER GENERATION CORPORATION LIMITED

PROJECT
IB THERMAL POWER STATION 2 × 660 MW UNITS 3 & 4
BANHARPALI, JHARSUGUDA ODISHA – 768234 INDIA

OWNER'S CONSULTANT
DEVELOPMENT CONSULTANTS PRIVATE LIMITED
DEVELOPMENT CONSULTANTS HOUSE
BLOCK-DG/4, SECTOR-II, SALT LAKE, KOLKATA – 700 091

BOP CONTRACTOR VENDOR

BGR ENERGY SYSTEMS LIMITED
LARSEN & TOURBO LIMITED
CHENNAI - INDIA

NAME SIGN DATE SHEET NO.OF

PPD. K.P.KRISHNAPRAKASH K.P.K 7-8-2015
SHEETS

CHD. S.SUBAHGAR S.S 7-8-2015 A4

APPD. N.SATISH N.S 7-8-2015 9
DEPT. SCALE WEIGHT (KG) REF.TO ASSY. DRG. ITEM NO. NO.OF
ITEMS
N.A N.A N.A N.A
CODE -
TITLE CARD BGR DOCUMENT NO:. REV.

GID - 208- CI - EAC- BS -54131

CONTROL PHILOSOPHY FOR PADDLE FEEDER CODE 2
NA SHEET 01 OF 09
 L&T Metallurgical & Material Handling
EDRC

L&T DOC NO- O15147-M-BM-EQ-DC-0008 DATE

PROJECT: BGRESL-OPGCL PF
BGRESL DOC NO- GID-208-CI-EAC-BS-54131 19.07.16
CHECKED SHEET
TITLE: CONTROL PHILOSOPHY OF DESIGNED
PADDLE FEEDER 2 of 9
BSU/MKM/RK SKD/SVG

1.0 DESCRIPTION OF CONTROL/ OPERATIONS OF PADDLE FEEDER

4 numbers travelling paddle feeders (PF-1 & PF-2 for Conveyor 11A and PF-3 & PF-4 for Conveyor
11B) of self-contained, self-propelled design are considered to scoop out coal from the hopper.
Both in forward and reverse direction of the travel motion, at guaranteed (rated) capacity of 1400
MTPH. The system comprises the following main drives
C

 Paddle wheel (hydraulic drive driven by hydraulic power pack)

 Travel drive (Geared Motor with pole changing motor)
 Dust suppression system (Plain water type)
 Cable Drag Chain System for power feeding to Paddle Feeder

The feeder is designed to travel for a span of ~229.6 Mtrs (Nominal). BGR will provide three
phase 415 V supply from their substation up to the center point of the land-mounted junction
box. From this junction box, power is taken through flexible power cable via drag Chain to the
Local starter panel mounted on the paddle feeder machine. Flexible control cables, telephone
cable and UPS power supply cable from mid-point CJB to machine mounted micro PLC panel is also
taken through the same drag-chain.

Control Philosophy

The Paddle Feeder is designed to operate from Local starter panel mounted on the machine only.
The control is through non-redundant micro PLC system. PLC panel is part of the local starter
panel in a separate vertical mounted on individual Paddle Feeder. The machine operates in the
D
following modes of operation.

1. Auto Mode - B
In this mode of operation, the paddle feeder while reclaiming from the track hopper automatically
reverses its travel direction at the end of its travel when it encounters the end-of-travel limit switches or
if it encounters the other paddle feeder on the same track at a distance of about 5mtrs from it. The
reclaim conveyor in this mode has to be operational too.

B
2. Manual Mode
In this mode of operation the paddle feeder while reclaiming from the track hopper does not
automatically reverse its travel direction but comes to a stop if it encounters the end-of-travel
limit switches or if it is at a distance of 5mtrs from the other paddle feeder on same track. The
reclaim conveyor in this mode has to be operational too.
3. Maintenance Mode B
This mode of operation of the paddle feeder is employed when the machine needs to be
maintained/ serviced. In this mode of operation the paddle feeder is brought to its maintenance
bay by operating the travel drive of the machine manually to the maintenance bay by bypassing
the operational and backup limit switches. The interlocks with the rotor drive are disengaged
 L&T Metallurgical & Material Handling
EDRC

L&T DOC NO- O15147-M-BM-EQ-DC-0008 DATE

PROJECT: BGRESL-OPGCL PF
BGRESL DOC NO- GID-208-CI-EAC-BS-54131 19.07.16
CHECKED SHEET
TITLE: CONTROLPHILOSOPHY OF DESIGNED
PADDLE FEEDER 3 of 9
BSU/MKM/RK SKD/SVG
and the reclaim conveyor taking feed from the paddle feeders is not operational. The machine
operates in push-to-run mode and stops as soon as it encounters maintenance end limit switch.

These modes are selected by means of a selector switch mounted on the local starter panel.

 Field Devices

The Paddle Feeder comprises the following field device:

 Travel forward end limit switch
 Travel Forward over travel limit switch (Heavy duty V-lever)
 Travel reverse end limit switch
 Travel Reverse over travel limit switch (Heavy duty V-lever)
 Anti-collision limit switch (1 No. Non-contact type Anti-collision sensor with Reflector and 1
No. heavy duty mechanical V-Lever switch)
 Rope actuated stop switch B
 Maintenance Bay limit switch
 Paddle wheel speed sensor
 Machine long travel over speed switch

 Hydraulic power system limit switches

 Oil temp switch {high temp. alarm (HTA) at 600C& very high temp. trip (HTT) at 700C}
 Oil low level switch {low level low alarm(OLLA) & very low trip(OLLT)}
 Unhealthy Charge pressure switch, P/W PUMP (CP1 & CP2)
 High oil pressure flow reduction (FC1 & FC2)
 High oil pressure pump switch (High system pressure) (LR1 & LR2)
 Pump suction limit switch (SV)
 Clogging of filter (Boost line) (CS1)
 Clogging of return line filter (CS2 & CS3)
 Electrical displacement control (EDC)
 Pressure transmitter-line pressure sensing (DR)
 Speed indicator (SR)

 Dust Suppression system level switches

 DS tank low level switch
 DS tank high level switch
 DS tank permissive level switch
 L&T Metallurgical & Material Handling
EDRC

L&T DOC NO- O15147-M-BM-EQ-DC-0008 DATE

PROJECT: BGRESL-OPGCL PF
BGRESL DOC NO- GID-208-CI-EAC-BS-54131 19.07.16
CHECKED SHEET
TITLE: CONTROLPHILOSOPHY OF DESIGNED
PADDLE FEEDER 4 of 9
BSU/MKM/RK SKD/SVG
 Operation Philosophy

The machine travel can take place in two modes,

High speed- when the machine is required to take for maintenance.
Slow speed- when the machine is required to scoop the coal (normal operation)
The above speeds are required to be selected (by travel speed selector switch) before the actual
operation of the machine.

In order to operate the machine, first the following are required to be checked.

 Control supply healthy indication

 Hydraulic permissive indication available
 Emergency Switches not operated
 Down conveyor 11A/11B is running C

When the above conditions are met, the machine is ready for operation. The first motor to be
started shall be hydraulic air oil cooler motor along with main pump motor, which is done by
initiating the start command for HPP motor and hydraulic power pack motor 'on' is indicated on
the panel. The paddle wheel can be started, once the hydraulic motor is "on” and down
conveyor is in running condition, which is done by initiating the start command for Paddle
wheel. The travel drive can be started when the paddle feeder is running at minimum (set)
speed. B

A speed indicator has been provided for indication of paddle wheel speed. Discharge wheel
speed (for achieving feed rate 20% to 100%) shall be controlled through paddle feeder PLC by
adjusting the speed setting in touch screen HMI. C

Machine shall be operated through panel mounted touch screen HMI. All indications and
annunciations shall be on HMI. C

Digital meter has been provided for indication of flow rate of coal on down conveyor. B

In case of paddle wheel jamming condition for a sustained period (more than 4 sec), PLC system
stops the paddle feeder and also ensures actuation of alarm hooter. Pressing the reset push
button ensures hooter alarm 'off.

In case of electrical or hydraulic fault or overload condition occurs, paddle feeder shall be
automatically stops. C

In auto mode the centrifugal pump of dust suppression system shall be started when the
hydraulic pump for paddle wheel is operating. The system when selected in auto mode will
 L&T Metallurgical & Material Handling
EDRC

L&T DOC NO- O15147-M-BM-EQ-DC-0008 DATE

PROJECT: BGRESL-OPGCL PF
BGRESL DOC NO- GID-208-CI-EAC-BS-54131 19.07.16
CHECKED SHEET
TITLE: CONTROL PHILOSOPHY OF DESIGNED
PADDLE FEEDER 5 of 9
BSU/MKM/RK SKD/SVG
ensure main pump to start and in case of trip of the same due to overload, the standby pump
automatically starts to operate till the DS tank low level operates. Water spraying for dust
suppression will be activated, when the paddle wheel is 'ON', through solenoid valve.

Telephone on the paddle feeder machine shall be provided for tele-communication between
Paddle Feeder and Main CHP Control Room.
C

 Following are the interfacing signals considered with CHP PLC. B

1. Stop the track hopper conveyor 11A/11B command from paddle feeder to CHP PLC. C
2. Paddle feeder trip/emergency stop activated to CHP PLC
3. Paddle feeder running feedback to CHP PLC.
4. Track hopper conveyor running indication from CHP PLC.
5. Emergency stop from CHP PLC.
6. Coal feeding rate TPH from track hopper conveyor 11A/11B belt weigh scale in the form of (4-
20mA).
C

Provision is kept for automatic tripping of track hopper conveyor when travel speed is in excess of
rated speed (paddle feeder getting dragged). An over speed switch shall be provided for this
purpose.

 Interlocks
The following list identifies the primary operational interlocks associated with the machine:

a) The Paddle Wheel will not operate unless the conveyor belt is running.
b) The Paddle feeder will not travel unless the Paddle wheel is rotating.
c) The hydraulic pump will not work if the protection system are not healthy (refer hydraulic
write-up)
D
d) Paddle feeder shall run only when dust suppression system is healthy.

 Annunciation Window: B
Annunciation window with buzzer is provided to alert the operator in case of any fault. Following
are the fault conditions considered for annunciation window.
a) Paddle wheel drive fault
b) Long travel drive fault.
c) Anti-collision operated
d) Emergency stop operated
D
e) DSS system unhealthy.
 L&T Metallurgical & Material Handling
EDRC

L&T DOC NO- O15147-M-BM-EQ-DC-0008 DATE

PROJECT: BGRESL-OPGCL PF
BGRESL DOC NO- GID-208-CI-EAC-BS-54131 19.07.16
CHECKED SHEET
TITLE: CONTROLPHILOSOPHY OF DESIGNED
PADDLE FEEDER 6 of 9
BSU/MKM/RK SKD/SVG

2.0 OPERATION OF HYDRAULIC SYSTEM OF PADDLE FEEDER

2.1 GENERAL

Paddle wheel drive circuit is closed one. Speed of Paddle wheel drive is determined by the
flow from electronic control variable displacement axial piston pump mounted on power pack. Main
pump provides flow to drive the paddle wheel motor and intrigated boost pump provides flow for
oil cooling circuit. The electronic control card control swash plate displacement thus controlling flow
which subsequently varies the speed of the plow drive between 3 to 12 rpm.

Cooler is provided in return line circuit to maintain oil temperature level below 60 0C.
Hydraulic system is also provided with other mandatory accessories like air breather, level gauge
etc.

2.2 PADDLE WHEEL OPERATION

During cold start, the cooler to be started. The main pumping unit electric motor to be
started at main pump in off-loaded condition. It has to be ensured the suction valve is in open
condition. At that time boost & control pressure is above 28 bar.
Electronic control variable displacement axial piston pump shall be operated based on
command provided to control card from machine PLC. Command shall be provided through
potential free contact based on operational requirement. There will be an electronic ramp 4-5 sec
in the control card to reach the desired paddle wheel speed.
Normal operating pressure in the system is ~ 215 bars at 3 to 12 rpm as required to achieve
desired TPH.
If the system pressure increases (due to over loading on Paddle wheel at difficult situation
the pressure switch set at 180 bar-reduces the speed of Paddle wheel drive to 5 rpm (max). During
extreme difficult situation (stall condition during jamming of paddle wheel) the pressure switch set
at 220 bar will off load the main pump with a time delay of 2sec. If the jamming situation
continues further the machine shall be stopped and to be moved in reverse direction (i.e. LT
opposite) with reversing (anti clockwise) the paddle wheel (This operation will happen
automatically in case of auto mode). The machine should be moved in reverse direction for a time
span of 20 sec @5M/min LT speed and it should start in normal cutting operation with forward LT
speed & clock wise paddle wheel rotation. If the jamming is not overcome the machine should be
operated in the same approach again one or two times. If the jamming situation persists then trip
the Paddle wheel by off loading the pump & Long Travel drives stop. The system will get an error

B
 L&T Metallurgical & Material Handling
EDRC

L&T DOC NO- O15147-M-BM-EQ-DC-0008 DATE

PROJECT: BGRESL-OPGCL PF
BGRESL DOC NO- GID-208-CI-EAC-BS-54131 19.07.16
CHECKED SHEET
TITLE: CONTROLPHILOSOPHY OF DESIGNED
PADDLE FEEDER 7 of 9
BSU/MKM/RK SKD/SVG
feedback “Paddle Wheel Jam”. Further, machine can be restarted after overcoming the jamming
situation.

The system pressure can be checked at pressure gauge by operating “push to read”
isolating valve. The pressure gauge shall always be connected with high pressure line through the
shuttle valve. One Pressure Transducer is provided to furnish continuous pressure display.

Built in cross line relief valves into the pump relieve the shock loading conditions and are
set at 250 bar. In case the pressure switch fails to operate at 220 bar, these relief valves limit
maximum pressure at 250 bar and oil blows over the valve to tank.

Cross port valve (Across the hyd. motor) can be opened for toeing / free-wheeling the plow
wheel in case of emergency. Built- in Purge valve take a portion of fluid from low pressure leg and
passes this through its relief which is set at 20 bar, and then back to tank, air blast oil cooler and
return line filter. Removed fluid gets replenished by boost pump.

2.3 Travel Drive Operation

On start up, first check the down conveyor is in running condition & paddle wheel is
rotating then travel can be started.
LT drive arrangement is provided with direct shaft mounted Geared Motor. LT drive having
two speed variation 2.5 & 5 M/Min shall be obtained by means of pole changing electric
motor. LT drive is provided with integral double disc brake with spring.
2.4 SYSTEM PROTECTION

The Hydraulic system is protected by the following:

1) Level switch at low level for emergency alarm & stop condition.

2) Temperature switch – opens on high temperature and should be considered as an

emergency stop condition if temperature rises beyond 700C.

3) Electrical clogging indicator of return filter gives electrical alarm if its element gets
clogged. Electrical clogging indicator of boost filter gives electrical alarm if its element gets
clogged.

4) The pressure switch, which are provided in plow wheel drive, if gets operated at 180 bar
continuously for 5 sec. Will send electrical signal which will reduce plow wheel speed by
sending electrical signal which will partial off load through the control card & servo
 L&T Metallurgical & Material Handling
EDRC

L&T DOC NO- O15147-M-BM-EQ-DC-0008 DATE

PROJECT: BGRESL-OPGCL PF
BGRESL DOC NO- GID-208-CI-EAC-BS-54131 19.07.16
CHECKED SHEET
TITLE: CONTROLPHILOSOPHY OF DESIGNED
PADDLE FEEDER 8 of 9
BSU/MKM/RK SKD/SVG
solenoid of pump thus reducing flow. Simultaneously it will stop LT drive by sending
electrical signal which will de-energize the servo solenoid of pump thus stopping flow.

5) The pressure switch, which are provided in plow wheel drive, if gets operated at 220 bar
continuously for 5 sec. Will send electrical signal which will de-energize the servo solenoid
of pump thus stopping flow.

6) If the boost pressure is below 15 bar, pressure switch will then trip all the pumps.

2.5 TECHNICAL SPECIFICATION OF DRAG CHAIN B

Type : E-CHAIN
Length of the Energy Chain 1 : ~119m.
Length of the Energy Chain 2 : ~119m.
Bending radius : 400 mm (max.)
Width of chain : 200 mm. (max.) for each chain
Degree of rotation for which
Drag chain is designed : 90 (at midpoint of track hopper)
Max. Push/pull force during
Operation : ~1.5 KN

Drag chain arrangement is used in Paddle feeder’s traverse movement. In Paddle feeder,
the Carriage structure i.e., the main frame is mounted on the wheel & axle type drive
arrangement through which entire structure will move longitudinally above rail. Drag
chain arrangement is used to provide flexibility to the electrical cables in between moving
machine & fixed cable support structure. For general arrangement refer indicative sketch
furnished below.

INDICATIVE ARRANGEMENT OF DRAG CHAIN

 L&T Metallurgical & Material Handling
EDRC

L&T DOC NO- O15147-M-BM-EQ-DC-0008 DATE

PROJECT: BGRESL-OPGCL PF
BGRESL DOC NO- GID-208-CI-EAC-BS-54131 19.07.16
CHECKED SHEET
TITLE: CONTROL
PHILOSOPHY OF DESIGNED
PADDLE FEEDER 9 of 9
BSU/MKM/RK SKD/SVG

The Drag chain assembly consists of a fixed and a moving end. The fixed end is attached
to the track hopper wall, whereas the moving one is attached to the Paddle Feeder frame
(with the help of an arm connected with the machine) which moves along with the Paddle
feeder machine. Indicative cross sectional view furnished below to show the arrangement.

CROSS SECTIONAL SKETCH OF DRAG CHAIN